For many, in wheel motors offer a panacea for vehicle design However history shows the delivery of an acceptable in wheel motor is a deeply challenging task which is dedicated to understanding aggressive torque and speed requirements behind demands on vehicle performance such as high speeds or sustained hill climb, and even aggressive driving, all of which are allowed by delivery of high continuous torque, limited in wheel packaging space, harsh environment, and safety requirements Protean Electric is entirely focussed on overcoming these challenges and believes that, with its novel technology, it has delivered a product that will allow vehicle manufactures to exploit the benefits of in wheel motors Protean's in wheel solution is based on a direct drive, permanent magnet brushless machine with an outer rotor High torque is delivered from a space envelope based on high ratio between the motor radius and axial length and the key to maintaining this high continuous torque is effective thermal management of the motor Power electronics together with control circuitry is integrated into the motor architecture, while the wheel bearing provides the mounting point for the motor This paper offers a holistic view of an in wheel motor design with special attention to overcoming the design challenges presented by harsh operating environments, high performance demands and safety aspect.7 Conclusions The design of Protean's electric motor for in-wheel application is based on a modular approach [5], which offers advantages for vehicle safety. The motor is divided into multiple sub-motors, each powered by its own power module and controlled by an independent control circuit. As a consequence, a single failure results in only a fraction of the torque loss, meaning that the induced yaw moment on the vehicle will be within the safety limits of the vehicle. The design solution is based on a direct drive, permanent magnet brushless machine with an outer rotor. High torque is delivered from a space envelope based on 3:1 ratio between the motor radius and axial length. Power electronics together with control circuitry is integrated into the motor architecture, while the wheel bearing provides the mounting point for the motor. The motor is fully seal against ingress of particles to ensure integrity during motor exposure to harsh environmental conditions and to fulfil the operational lifetime requirements of all sub components. High performance requirements and high power density are achieved with effective thermal paths, which offer space for improvement around better material selection to allow even more efficient thermal energy transfer through the machine. The question of unsprung mass has been answered through analysis showing that the nature of the changes imposed on vehicle dynamics can be addressed with even conventional development process, if needed. The result of this concentrated engineering effort is a highly efficient motor unit, having a combined motor and inverter efficiency in excess of 93% and combined drive cycle efficiency in excess of 85%, high power dense and high torque machine, with output torque shown in Figure 7, able to withstand required operating and environmental conditions of vehicles, ready to be adopted by vehicle manufacturers.


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